Telescoping box construction

ABSTRACT

A telescoping box is formed from two parts, a top part and a bottom part. The bottom part of the box has a bottom wall and a sidewall extending upwardly from the bottom wall. Likewise, the top part has a top wall and a sidewall depending from the sidewall. A collar is located to the interior sidewall and extends above the top edge of the bottom sidewall. When the box is closed, the bottom edge of the top sidewall rests upon the top edge of the bottom sidewall to result in a flush outer surface. The collar and bottom sidewall are formed from multiple panels. The collar and sidewall may te formed from a single blank. The sidewalls and collar are provided with fold lines to facilitate the sidewalls assuming an arcuate shape. When folded, the fold lines are hidden from view when the box is closed.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a divisional of application Ser. No.09/643,397, filed Aug. 22, 2000.

FIELD OF THE INVENTION

[0002] The invention relates to a structure and method for making boxesof a complicated structure.

BACKGROUND OF THE INVENTION

[0003] Boxes are a very common way to package goods. Often, the goodssold in the boxes remain in the boxes after purchase so that the boxserves as storage for the goods. For this reason, ornamental and sturdyboxes are desirable.

[0004] Boxes have been a popular form of container for a very long time.The light weight, strength and easy manufacture of boxes makes them apopular choice. The prior art has a great variety of available shapes,sizes, construction and features. One such prior art box is discloses inU.S. Pat. No. 1,678,958 (Schleicher). Schleicher discloses a round boxhaving a sidewall 4 connected to the top wall 1 and bottom wall 3 by aseries of tabs 7. Similarly, U.S. Pat. No. 1,772,878 (Schleicher)discloses a box having a sidewall 11 connected to bottom wall 2 by tabs12. The sidewall is arcuate and provided with several fold lines 15, 18,21, 22 to form bends in the sidewall.

[0005] Graves et al., U.S. Pat. No. 2,341,338 discloses a containerhaving a bottom section with a lower wall 10 and an upper section havingan upper wall 11 separated by pulling a string 13. A collar 2 extendsabove the lower wall 12 and is telescopicly received within the upperportion 9.

[0006] U.S. Pat. No. 2,457,198 (Bell) discloses a circular containerhaving a crimped outer surface 13. Tabs 18 engage slots 19 to retain thecontainer in a circular configuration.

[0007] Further, none of the prior art discloses a simplified method offorming complex boxes and none disclose a means of forming boxes witharcuate walls in which the bunching effect may be effectively hidden.

[0008] Further, none of the prior art patents discloses a telescopingbox having an upper wall and a lower wall and a collar portion, thecollar and lower portion being formed from multiple panels.

SUMMARY OF THE INVENTION

[0009] It is an object of the invention to provide a telescopingcontainer having a smooth outer surface when closed.

[0010] It is another object of the invention to provide a multilayer boxhaving a smooth, curved surface.

[0011] It is another object of the invention to provide a box having astrong construction.

[0012] It is yet another object of the invention to have fold lines withapertures to accommodate excess material caused by bending panels intoan arcuate shape.

[0013] It is still another object of the invention to provide a boxhaving curved sidewalls without any visible score lines.

[0014] It is yet another object of the invention to provide a box thatis easy and inexpensive to manufacture.

[0015] These and other objects of the invention will become apparentafter reading the detailed description of the invention that follows.

[0016] A telescoping box is formed from two parts, a top part and abottom part. The bottom part of the box has a bottom wall and a sidewallextending upwardly from the bottom wall. Likewise, the top part has atop wall and a sidewall depending from the top wall. A collar is locatedinteriorly of the sidewall and extends above the top edge of the bottomsidewall. When the box is closed, the bottom edge of the top sidewallrests upon the top edge of the bottom sidewall to result in a flushouter surface.

[0017] The collar and bottom sidewall are formed from multiple panels.The collar and sidewall may be formed from a single blank. The sidewallsand collar are provided with fold lines to facilitate the sidewallsassuming an arcuate shape. The fold lines are hidden from view when thebox is closed.

[0018] Both the collar and upper sidewall are provided with tabs thatextend along, and are secured to, the bottom or top wall. When thecollar and bottom sidewall are formed from separate blanks, the bottomsidewall also has tabs securing it to the bottom panel. A strong,aesthetically pleasing box results that can be repeatedly used to storeitems.

[0019] Fold lines are formed on the interior panel of the multilayerconstruction. The fold lines have apertures. When the sidewalls are bentinto an arcuate shape, the excess material that results from the bendingprocess fits into the apertures. The result is a smooth exteriorsurface. When in the blank form, all the panels have the same length.When folded, the inner panel has the smallest radius of curvature of allthe layers. The inner layer will have material that bunches while theouter layer will be stretched across the arc. The excess material of theinner layer fits into the apertures to result in a smooth surface.

[0020] In accordance with the teachings of this invention there isprovided a container, which comprises a bottom wall, a lower sidewallextending upwardly from the bottom wall, with the lower sidewall havingan outer panel and an inner panel. There is also provided a collarlocated inside of the lower sidewall, the collar having a height greaterthan a height of the said lower sidewall, said collar having a firstpanel and a second panel.

[0021] In another aspect of this invention there is provided a methodfor forming a multilayer arcuate sidewall which comprises the steps offorming creases on an interior panel, forming apertures in the foldlines, bending the multilayer sidewall into an arcuate shape, andallowing excess material from an interior sidewall to enter saidapertures in the middle sidewall.

[0022] In yet another aspect of this invention there is provided acurved sidewall which comprises an inner panel, an outer panel and amiddle panel between the inner and outer panels. Apertures are formed inthe middle panels, material from the inner panel entering the aperture.

[0023] In still another aspect of this invention there is provided acurved sidewall which comprises a first panel forming an interior of thesidewall, a second panel connected to the top of the first panel andextending downwardly, a third panel connected to the bottom of thesecond panel and extending downwardly, a fourth panel connected to thebottom of the third panel and extending upwardly, a fifth panelconnected to the top of the fourth panel and extending downwardly, and asixth panel extending from the bottom of the fifth panel and extendingupwardly. Apertures are formed in the third and fifth panels. Materialfrom the first panel enters the apertures when the sidewall is formedinto a curved shape.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024]FIG. 1 shows the preferred embodiment box constructed inaccordance with the principles of the invention in an open condition.

[0025]FIG. 2 shows the preferred embodiment box constructed inaccordance with the principles of the invention in a closed condition.

[0026]FIG. 3 shows a heart-shaped alternative embodiment of theinvention.

[0027]FIG. 4 is a cross section of the bottom sidewall and collar.

[0028]FIG. 5 is a planned view of blank used to make the box depicted inFIG. 1.

[0029]FIG. 6 is a detailed view of the tabs.

[0030]FIG. 7 is a cross section of a second embodiment of the bottomwall and collar.

[0031]FIG. 8 is a view of a section of a blank that forms the box.

[0032]FIG. 9 is a cross section of the collar and bottom wall when it isformed from two pieces.

DETAILED DESCRIPTION OF THE INVENTION

[0033] The box of the invention has a bottom part 1 and top part 2, andcan be seen in FIG. 1 in the open configuration. Seen in this figure isthe bottom panel 3, a lower sidewall 4, and the collar 6 extending abovethe lower sidewall 4. A shoulder 5 is formed by the top of the lowersidewall 4. Creases on the interior side of the collar facilitate thebending of the collar into an arcuate shape. The top part 2 has a toppanel 9 and a depending upper sidewall 8. The closed configuration shownin FIG. 2 is formed when the top part 1 and the bottom part 2 are joinedto close the box. As can be seen in this view, the bottom of the uppersidewall 8 rests on the shoulder 5 of the lower sidewall to form a flushsurface.

[0034]FIG. 3 shows an alternative form of the box. The box is heartshaped and has a bottom wall 13 with an upstanding lower sidewall 14.The top surface of the lower sidewall forms a shoulder 15. A collar 16extends above the shoulder of the lower sidewall. Creases 17 are formedon the interior of the collar and creases 20 are formed on the outsideof the collar 16. When the box is closed, the collar is covered by theupper sidewall and no creases are visible.

[0035] The structure of the collar and lower sidewall is seen in crosssection in FIG. 4. The collar is formed by a first panel 29 and a secondouter panel 30 connected to one another by a fold line 31. The secondpanel 30 has creases 32 to facilitate the bending of the panels into anarcuate shape. Tabs 23 attach the lower sidewall to the bottom panel. Aninner panel 24 is connected to the tabs along a first fold line 19. Asecond fold line 25 connects the inner panel 24 to the outer panel 26.As can be seen, a space is created between the inner panel 24 and theouter panel 26. To create this space, the second fold line 25 can be adouble fold line as is well known in the art. A middle panel 28 fitsinto the space between the inner panel 24 and outer panel 26. The middlepanel 28 is connected to the outer panel 26 along third fold line 27.The inner panel 24, middle panel 28, outer panel 26, first panel 29 andsecond panel 30 can be adhered to one another with adhesive to maintainthem in position and add to the structural integrity of the box.

[0036] The blank for forming the lower sidewall is shown in FIG. 5. Foldline 25 connects tabs 23 to the inner wall panel 24. Fold line 27connects the inner wall panel 24 to an outer panel 26. The middle panel28 is connected to the outer panel 26. The inner panel 24 is providedwith creases 8 and the outer panel 26 is provided with creases 9. Themiddle panel has creases 10 formed on the outer surface that allow thepane to form a convex shape. Perforations 11 are also formed on themiddle panel. In addition to the creases, cutouts 12 are formed in themiddle panel 28.

[0037] The inner panel 24, middle panel 28, and outer panel 26 all havethe same length when in the blank form. When they are folded into anarcuate shape of the box, however, the inner panel has the smallest rateof curvature. The arc length formed by the inner panel is shorter thanthat formed by the middle panel 28 or outer panel 26. When formed, theouter panel is stretched across the middle panel. When the inner panelis folded into the arcuate shape, the excess material formed by virtueof the tighter curvature of the panel fits into the cutouts in themiddle panel. The cutouts form areas for the excess material to go andallow the three panels that form the sidewall to have a smooth surface.

[0038] A detailed view of an alternative embodiment is shown if FIG. 6.The lower sidewall is shown having tabs 122 connected along fold line133 to a first panel 123. The first panel 123 is connected to the outerpanel 124 along fold line 134 and to middle panel 125 along fold line135. Creases 129 run along the height of the blank and cutouts 132 areformed within the middle panel 125.

[0039] An embodiment having the collar and lower sidewall formed from asingle blank is shown in cross section in FIG. 7. The collar/sidewallhas tabs 43 to attach the collar/sidewall to the bottom panel. A firstpanel 44 extends upwardly from the tabs and is connected to the tabs byfold 42. A fold line 45 at the top of the first panel 44 connects it toa second panel 46. The second panel 46 has a fold line 47 connecting itto a third panel 48 that extends upwardly. The third panel 48 isconnected to a fourth panel 50 by fold line 49. The fourth panel 50extends downwardly to terminate in a fifth fold line 51. The fifth foldline connects a fifth panel 52 to the fourth panel 50. The fifth panelextends upwardly and extends between the first panel 44 and the fourthpanel 50. As in the earlier embodiment, adhesive is used between thepanels that lay against one another to increase the structural integrityof the box.

[0040] Creases 64 are provided on the interior surface of the firstpanel 44 and protrude on the inside. Creases 65 are provided on theexterior of the second panel 46 that extends above the fold line 49 andprotrude on the inside. On the exterior surface of the second panel 46below the third fold line 48, creases 66 are cut to protrude outwardly.Lastly, creases 67 are formed on the interior surface of the third paneland protrude inwardly. When the cover is placed onto the lower part ofthe box, the fold lines are covered and not visible.

[0041] The section of the blank used to make the container is shown inFIG. 8. All of the various fold lines in the panels are seen. Also seenin this view is the locking tab 71 and 72 used to secure the sidewall toitself after folding. The locking tabs engage slits or are adhered tothe opposite edge of the sidewall when assembled. In addition to thecreases, there are slots 73, 74 and 78 that provide openings. When theblank is bent into an arcuate shape, the slots provide areas formaterial to move into.

[0042] In addition, there are a series of cuts 75 in the fifth panel 52.These cuts penetrate approximately half the thickness of the panel andmake the material more pliable. The cuts can be replaced byperferations. Creases 76 and 77 traverse the fourth panel 50,. Creases77 are colinear with the slot 74 on the fifth panel 52.

[0043] In FIG. 9, another embodiment of the invention is depicted. Inthis embodiment, the lower sidewall 81 is formed by a center panel 87having a lower fold line 91 and an upper fold line 90. The upper foldline 90 forms a shoulder. A pair of wing panels 88 and 89 are attachedto the center panel 87 by the upper and lower fold line. The wing panelsare folded over against the center panel and are on the interior of thecenter panel. The collar 82 has tabs 83 for attaching the collar to abottom panel. A fold line 80 attaches the tabs 83 to a first panel 84. Asecond panel 86 is connected to the first panel 84 by a fold line 85.The result is a two layer lower sidewall and two layer collar. Thepanels can be adhered to one another to improve their structuralintegrity.

[0044] While the invention has been described with reference topreferred embodiments, modifications and variations would be obvious toone very skilled in the art. The invention is not to be limited to theexact embodiments disclosed but encompasses variations that do not fallwithin the scope of the invention.

What is claimed is:
 1. A method for forming a multilayer arcuatesidewall, comprising: forming creases on an interior panel, formingapertures in the fold lines, bending the multilayer sidewall into anarcuate shape, and allowing excess material from an interior sidewall toenter said apertures in the middle sidewall.
 2. The method of claim 1,wherein said creases are formed on the interior side of the interiorpanel.
 3. The method of claim 1, wherein said creases are formed on theexterior side of the interior panel.
 4. A curved sidewall, comprising aninner panel, an outer panel and a middle panel between said inner andouter panels, and apertures formed in said middle panels, material fromsaid inner panel entering said aperture.
 5. The curved sidewall of claim4 wherein said apertures are formed in fold lines in said middle panel.6. The curved sidewall of claim 5, wherein said fold lines are vertical.7. The curved sidewall of claim 4, wherein said outer panel is connectedto said middle panel by a fold line and said middle panel is connected.8. The curved sidewall of claim 4 further comprising perforations insaid middle panel.
 9. The curved sidewall of claim 8, wherein saidperforations are spaced from said apertures.